Apparatus for producing multicolor patterns and sheet material produced thereby

ABSTRACT

There is disclosed an extrusion assembly for fabricating synthetic plastic sheet material having differentially colored bands which utilizes an extrusion die block having a chamber of streamlined non-circular cross section in which is disposed a pair of sleeve members of non-circular stream-lined cross section. The matrix resin is supplied to the die block chamber on the opposite side of the die chamber from the extrusion orifice and the differentially colored resin is supplied to the sleeve members. Each of the sleeve members has a pair of bores therein, one of which receives the differentially colored resin and communicates with the other which in turn has discharge openings in the surface thereof adjacent the extrusion orifice. The sleeve members are spaced apart so as to provide a channel therebetween and are spaced from the walls of the die chamber so as to provide channels thereabout whereby matrix resin will flow both between and about the sleeve members. Flow diverting bars are disposed within the die chamber to cause the matrix resin to flow towards the discharge openings from the sleeve members and encapsulate the differentially colored resin issuing therefrom. Means is provided in the feed bores to equalize substantially the flow of resin from the feed bores to the other bores in the sleeve members over substantially the entire length thereof. The discharge bores have means therein operating to intermittently discharge resin through the discharge openings. The intermittent discharge means may be independently driven and may be driven in different directions so as to provide a basketweave design, bands of color at right angles to each other and the like. Three extruders may be utilized to provide two color bands with different colors being supplied to each of the sleeve members.

United States Patent [1 1 Randall 14 1 Feb. 19, 1974 APPARATUS FOR PRODUCING MULTICOLOR PATTERNS AND SHEET MATERIAL PRODUCED THEREBY Robert E. Randall, Kensington, Conn.

[75] Inventor:

[73] Assignee: Rowland Products Incorporated,

Kensington, Conn.

[22] Filed: July 21, 1972 [21] Appl. N0.: 273,732

[52] U.S. Cl 425/132, 425/376, 425/462 [51] Int. Cl B29f 3/12 [58] Field of Search... 425/462, 131, 132, 375, 376,

Primary ExaminerR. Spencer Annear Assistant Examiner-Mark Rosenbaum [5 7 ABSTRACT There is disclosed an extrusion assembly for fabricating synthetic plastic sheet material having differentially colored bands which utilizes an extrusion die block having a chamber of streamlined non-circular cross section in which is disposed a pair of sleeve members of non-circular stream-lined cross section. The matrix resin is supplied to the die block chamber on the opposite side of the die chamber from the extrusion orifice and the differentially colored resin is supplied to the sleeve members. Each of the sleeve members has a pair of bores therein, one of which receives the differentially colored resin and communicates with the other which in turn has discharge openings in the surface thereof adjacent the extrusion orifice. The sleeve members are spaced apart so as to provide a channel therebetween and are spaced from the walls of the diechamber so as to provide channels thereabout whereby matrix resin will flow both between and about the sleeve members. Flow diverting bars are disposed within the die chamber to cause the matrix resin to flow towards the discharge openings from the sleeve members and encapsulate the differentially colored resin issuing therefrom. Means is provided in the feed bores to equalize substantially the flow of resin from the feed bores to the other bores in the sleeve members over substantially the entire length thereof. The discharge bores have means therein operating to intermittently discharge resin through the discharge openings.

The intermittent discharge means may be independently driven and may be driven in different directions so as to provide a basketweave design, bands of color at right angles to each other and the like. Three extruders may be utilized to provide two color bands with different colors being supplied to each of the sleeve members.

20 Claims, 15 Drawing Figures PHTENTED FEB 19 1974 SHEH10F4 FIG. 12

sum 2 BF 4 QUIT 2 En on 9 mm ow S vm 3 cm mm 9 W mo 4% mv mm 2 mm m1 7 mm Y on 8 APPARATUS FOR PRODUCING MULTICOLOR PATTERNS AND SHEET MATERIAL PRODUCED THEREBY BACKGROUND OF THE INVENTION For more than a decade, there has been considerable effort devoted to the producing of synthetic thermoplastic sheet material having differentially colored bands or layers therein. The materials originally developed employing differentially colored bands are of the type illustrated in US. Pat. No. 2,985,556 granted May 23, 1961 to William P. Rowland and it can be seen that the bands of the differentially colored material extended in a direction generally parallel to the direction of extrusion. Other techniques for introducing differentially colored material in the body of the extruded sheet are shown in US. Pat. No. 2,632,204 to Murray and US. Pat. No. 2,803,041 to Hill et al.

For some applications, it is extremely desirable that the differentially colored materials not extend in a parallel pattern to the direction of the extrusion and this is particularly so in the optical frame industry wherein patterns of varying appearance are constantly desired. Various techniques have been proposed to provide interruption in an otherwise parallel pattern for the differentially colored material, among which is that illus trated in US. Pat. No. 3,274,646 to Krystof. Techniques for producing unusual multilayered and swirl patterns are described in US. Pat. No. 3,443,278 and US. Pat. No. 3,531,828 to Jan P. Nauta and US. Pat. No. 3,422,175 to William P. Rowland.

One of the most popular patterns over the past years has been a Havana pattern which effectively comprises a basketweave design wherein differentially colored material from a crosshead extruder is discharged from two series of vertically spaced ports fed intermittently by means of screws or the like. Such designs have proven quite popular but there have been very serious limitations as to the width of the sheet material which could be produced thereby due to the problems of maintaining adequate even flow of resin across the series of small ports employed.

In addition, there have been problems in maintaining reasonably distinct bands of the differentially colored material because of the tendency toward smearing as the streams of differentially colored resin and matrix resin meet and blend together.

It is an object of the present invention to provide novel apparatus for producing multibanded patterns of differentially colored resin disposed within a matrix resin and in which the bands of differentially colored material are of substantially uniform intensity and dimension throughout the width of the sheet material.

It is also an object to provide such apparatus in which the bands of differentially colored resin are relatively distinct and substantially free from smearing.

Another object is to provide such apparatus wherein two differentially colored resins may be utilized to provide the bands for a three color sheet material.

Still another object is to provide such apparatus in which the differentially colored bands may cross at substantially right angles.

A further object is to provide a method for achieving basketweave or mesh designs of differentially colored resins wherein the bands of differentially colored resin are relatively free from smearing and relatively uniform in intensity over the width of the sheet material.

SUMMARY OF THE INVENTION It has now been found that the foregoing and related objects may be readily obtained in an extrusion assembly for fabricating sheet material having differentially colored pattemstherein and comprised of an extrusion die block having a chamber therein generally of streamlined non-circular cross section. An elongated extrusion orifice is provided in one surface thereof and a discharge passage extends between the chamber and the extrusion orifice. The chamber has enlarged intermediate portion of generally curvilinear configuration extended beyond both sides of the discharge passage and streamlined surfaces which taper from the enlarged portion to the discharge passage.

A first feed conduit extends through the die block to the chamber at a point spaced to the opposite side thereof from the discharge passage and is adapted to supply a matrix of fluid synthetic thermoplastic resin. At least one additional feed conduit extends through the die block to the chamber and has a portion within the die member extending generally parallel to the extrusion orifice and it is adapted to supply a differentially colored fluid synthetic plastic resin.

A pair of sleeve members are provided in the die chamber and extend generally parallel to the extrusion orifice. They have streamlined, non-circular outer surfaces extending in spaced relationship to the surfaces of the enlarged intermediate portion of the die chamber and they are spaced apart to provide a passage therebetween. The sleeve members each have a feed bore therein communicating with the additional feed conduit, and a main bore spaced therefrom towards the discharge passage with a flow passage therebetween. The sleeve members have a multiplicity of discharge openings extending from the main bore to the outer surface thereof adjacent the discharge passage and defined by diverging walls to provide an increased width adjacent the outer surface. The sleeve members are also provided with pressure compensating means to provide substantially uniform flow of resin over the length of the feed and main bores. Distributor elements are seated in the main bores of the sleeve members and provide intermittent flow of differentially colored fluid synthetic thermoplastic resin through the multiplicity of discharge openings in the sleeve members. The assembly includes means for driving the distributor elements to provide such intermittent. flow.

A flow diverter member is provided in the chamber adjacent the discharge passage and has trailing surfaces extending in spaced relationship to the surfaces of the sleeve members adjacent the discharge openings of the sleeve members and it has projecting portions at the discharge openings to direct flow of matrix resin towards the discharge openings. The flow diverter member also has leading surfaces converging towards the discharge passage and spaced from the streamlined surfaces of the die chamber to provide passages therebetween. As a result, matrix fluid synthetic thermoplastic resin entering through the first conduit into the upstream end of the die chamber is caused to flow about and between the sleeve members as a differentially colored fluid synthetic thermoplastic resin being fed through the additional conduit to at least one of the feed bores is intermittently discharged through the discharge openings of the sleeve member. The differentially colored resin is wiped from the discharge openings by the matrix resin flowing thereabout to produce encapsulation thereof in the matrix resin.

In the preferred embodiment, the chamber of the die block has a configuration defined by concavely curvilinear intermediate surfaces providing the enlarged intermediate portion, substantially rectilinear trailing surfaces tapering therefrom to the first feed conduit and substantially rectilinear leading surfaces tapering from the curvilinear intermediate surfaces to the discharge passage. The flow diverter member has its trailing end defined by a pair of generally concavely arcuate surfaces with a land therebetween extending toward the passage between the sleeve members and converging leading surfaces extending generally parallel to the rectilinear walls of the die chamber to provide a flow passage therebetween. The trailing and intermediate surfaces of the die block chamber and the trailing end of the flow diverter member define a generally pear shaped configuration. In turn, the pair of sleeve members are each of generally tear drop configuration so as to cooperate with the pear shaped configuration.

The sleeve members each have discharge openings arranged in at least two rows along the length thereof and the discharge openings in the rows of each sleeve member are staggered. The rows are spaced generally to opposite sides of the passages between the leading surfaces of the flow diverter member and the die chamber streamlined surfaces. Most desirably, the projecting portions on the trailing surfaces of the flow diverter member extend into the discharge openings of that row adjacent to it, and additional flow diverter members are provided in the die chamber and have portions disposed at the discharge openings of the others of said rows.

In one embodiment, the pressure compensating means in the sleeves comprises manifold tubes seated within the feed bores and having a multiplicity of orifices therein providing communication to the flow passage between the feed bore and main bore, and the orifices increase in size towards the end of the feed bores spaced from the additional feed conduit.

In another embodiment, the pressure compensating means comprises an insert member within the feed bore which increases in cross section to the end thereof spaced from the additional feed conduit and thereby constricts the feed bore opening to increase the pressure of resin flowing therethrough and into the flow passage therefrom to the main bore.

In one embodiment, there are two additional feed conduits each connected to a feed bore in one of the sleeve members, and the additional feed conduits are adapted to supply two different streams of differentially colored synthetic thermoplastic resin to the sleeve members. To provide variations in pattern, the drive means for the distributor elements may drive the distributor elements in opposite directions of rotation or at different rates of rotation, or both.

In the method of the present invention, an elongated die chamber is provided having an extrusion orifice and a discharge passage communicating therebetween and fluid synthetic thermoplastic resin is supplied to the die chamber at a point spaced from the discharge passage. Differentially colored fluid synthetic thermoplastic resin is supplied at a multiplicity of points in the die chamber spaced along the length thereof and between the point of supply of the first mentioned fluid synthetic plastic resin and the discharge passage. These points are spaced both above and below the center line of the die chamber, and the resin is supplied intermittently at the spaced points to produce pulses of color.

The flow of differentially colored resin to the spaced points is controlled to provide substantially uniform amounts thereto along the length thereof, and the first mentioned resin is caused to flow above and below the spaced points of introduction of the differentially colored resin and to flow towards the points of supply to encapsulate the differentially colored resin at the points of supply. The resultant composite stream is extruded and has the differentially colored synthetic thermoplastic resin encapsulated within a matrix of the first mentioned synthetic thermoplastic resin, and the differentially colored synthetic thermoplastic resin provides intersecting bands of differential color along the length of the extruded composite stream.

In one embodiment of the method, the points of supply of the differentially colored fluid synthetic thermoplastic resin are helically moved a limited distance along the length of the die chamber. The direction of helical movement of the points of introduction above the center line of the die chamber may be opposite to the direction of helical movement of the points below the center line of the die chamber, or the same. The speed of helical movement of the points of introduction above the center line of the die chamber may differ from the speed of the helical movement of the points below the center line of the die chamber. The differentially colored fluid synthetic thermoplastic resin supplied at the points above the center line may be a first differential color and that supplied below the center line may be of a second differential color, thereby producing a three-color synthetic plastic material having intersecting bands of two different colors.

The differentially colored extruded thermoplastic sheet material comprises a matrix of synthetic thermoplastic resin and a multiplicity of bands of differentially colored thermoplastic resin encapsulated therein. Some of the bands extend angularly to others of the bands so as to intersect therewith and provide a grid pattern. The bands of one angular orientation are disposed at a depth within the matrix resin different from that of the other angular orientation and a multiplicity of bands of each orientation is provided across the width of the sheet material. The bands are substantially uniform in volume or area across the width of the sheet material and substantially free from smearing.

As has been indicated previously, the grid pattern can be varied to produce different angular arrangements of the intersecting bands and two differentially colored resins can be utilized to produce intersecting bands of different colors.

The present invention is advantageously employed with various synthetic thermoplastic materials such as cellulose acetate and cellulose acetate/butyrate. Various dyes and pigments may be used to provide color or varying density of coloration to one or both plastic streams to achieve the visual differntiation in color, refraction or transparency.

The term differentially colored material is intended to encompass materials which are visually distinguishable from the material of the body of the sheet to provide a visual pattern effect including the use of colors or substantial lack of color distinct from that of the body of the sheet and the use of the same color but having distinct optical properties so as to produce variation in light refraction or transmission with resultant visual pattern effect.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a plan view of an extruder assembly embodying the present invention with the sheet material issuing therefrom fragmentarily illustrated;

FIG. 2 is a side elevational view of the die block assembly of the apparatus in FIG. 1 drawn to a greatly enlarged scale and with portions thereof in section to show internal construction;

FIG. 3 is a fragmentary sectional view of the die block assembly to a still further enlarged scale;

FIG. 4 is a front elevational view of only the sleeve members and restrictor bars in the die block assembly of FIGS. l-3 drawn to a scale somewhat enlarged from that of FIG. 2;

FIG. 5 is a sectional view along the line 5-5 of FIG. 4 and to a somewhat enlarged scale;

FIG. 6 is a similar sectional view along the line 66 of FIG. 4;

FIG. 7 is a front elevational view of the pressure compensating means utilized in the feed bore of the embodiment of FIGS. 2 and 3 with a portion thereof partially in section to reveal internal configuration;

FIG. 8 is a sectional view to a greatly enlarged scale of the pressure compensating means of FIG. 7 along the line 88 of FIG. 7;

FIG. 9 is a similar sectional view along the line 9-9 of FIG. 7 showing the increased size of the orifice;

FIG. 10 is a similar sectional view along the line l0-10 of FIG. 7 to show the further increased size of the orifice;

FIG. 11 is a front elevational view of an alternative embodiment of pressure compensating means for placement in the feed bore;

FIG. 12 is a fragmentary plan view of an extruder assembly embodying the present invention and adapted to produce three color sheet material;

'FIG. 13 is a plan view of sheet material produced in accordance with the present invention and employing the so-called Havana pattern;

FIG. 14 is a fragmentary view thereof to a greatly enlarged scale along a section transversely thereof; and

FIG. 15 is a plan view of another embodiment of sheet material produced in accordance with the present invention.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENT Turning now in detail to FIGS. l-l0 of the attached drawings, therein illustrated is an extruder assembly for producing a differentially colored synthetic plastic sheet material having spaced bands of a second color at two depths within the matrix ofa first color and especially adapted to produce a Havana pattern illustrated in FIGS. 13 and 14. AS seen in FIG. 1, an extruder assembly includes a main or matrix extruder generally designated by the numeral 10, a crosshead extruder generally designated by the numeral 12 and a die block assembly generally designated by the numeral 14 with the sheet material produced thereby being generally designated by the numeral 16.

The die block of the assembly 14 has a large chamber therein generally designated by the numeral 18, a first feed conduit 20 from the main extruder l0 and a second feed conduit 22 from the crosshead extruder 12. A discharge passage 24 extends from the chamber 18 to the extrusion orifice 26 (seen in FIG. 2) which is provided in the surface of the die block opposite that having the feed conduit 20. As also seen in FIG. 2, the dimension of the extrusion orifice 26 is controlled by the die lips 27 which may be adjusted by adjusting bolts (not shown). For purposes of clarity, illustration of heat exchange conduits, thermocouples, adjusting screws, drive mechanism for the screws and the like has been omitted.

As best seen in FIGS. 2 and 3, the feed conduit 20 opens into an enlarged manifold 28 of circular cross section extending across the length of the die chamber 18 so as to supply resin from the extruder 10 across the entire length thereof. The die chamber 18 is of generally pear-shaped cross section to provide a streamlined, non-circular configuration with a large central portion 30 of curvilinear, non-circular cross section with generally rectilinear trailing surfaces 32 extending from the manifold 28 and blending smoothly thereinto. Similarly, the die chamber 18 has generally rectilinear leading surfaces 34 extending from the curvilinear central portion 30 to the discharge passage 24.

Seated within the die chamber 18 are a pair of sleeves generally designated by the numeral 36 and of streamlined, generally tear shaped cross section. As can be seen, the sleeves 36 have a curvilinear leading surface 38 which cooperate with the curvilinear central portion 30 of the die chamber 18, and generally rectilinear outer trailing surfaces 40 which cooperate with the rectilinear trailing surfaces 32 of the diechamber 18 so as to provide a passage of relatively uniform spacing therebetween. The sleeves 36 have generally rectilinear opposed surfaces 42 and are spaced apart by spacing ribs 44 to provide a channel 45 therebetween aligned with the feed conduit 20 and the discharge passage 24. The sleeves 36 are also spaced from the Walls of the die chamber 18 by spacing ribs 46 on the outer surfaces thereof to provide channels 47 therebetween.

Each of the sleeves 36 has a relatively small diameter circular bore 48 in the trailing portion thereof and a relatively large diameter bore 50 in the leading portion thereof, and the two bores communicate through a feed passage 52. The small bore 48 comprises the feed bore and is in communication with the feed conduit 22; it has disposed therewithin a pressure compensating tube 54 which is provided with a multiplicity of circular apertures 56 along its length as best seen in FIGS. 7-10. The diameter of the circular apertures 56 increases from the inlet end of the bore 48 to the opposite end so that there is less restricted flow of the resin therethrough as the pressure drops along the length of the bore 48 with increasing distance from the feed conduit 22.

As best seen in FIGS. 4-6, the sleeves 36 each have two rows of staggered, elongated slot-like discharge openings 58a, 58b which have outwardly diverging sidewalls and through which the resin passes. Rotatably seated in the large diameter bores 50 are metering screws 60 with helical lands 61 which alternately discharge resin through the adjacent staggered discharge openings 58a, 58b of the two rows as the lands rotate thereby, thus producing intermittent and alternate discharge through the adjacent staggered openings of the two rows. The screws 60 are driven by suitable drive means (not shown) which is connected thereto outwardly of the die block 14.

Seated within the leading end of the die chamber is a flow diverter generally designated by the numeral 62 which has a streamlined configuration conforming to the adjacent surfaces of the die chamber 18 and sleeves 36. The leading surfaces thereof 70, 72 are rectilinear and extend generally parallel to the rectilinear leading surfaces 34 of the die chamber 18. The trailing portion thereof is substantially defined by a pair of concavely arcuate surfaces 64, 66 which intersect at a land 68 projecting into the channel 45 between the sleeves 36. Curvilinear lobes 74 serving as flow diverter members project at spaced points along the upper and lower ends of the flow diverter 62 into the discharge openings 58b of the upper sleeve 36 and discharge openings 58a of the lower sleeve 36, as viewed in FIGS. 2 and 3 of the appended drawings.

The flow diverter 62 is positioned within the die chamber 18 by suitable means on the ends thereof (not shown) mounted within the die block 14. For ease of fabrication, the flow diverter 62 is initially constructed with a cross section including the lobes 74 along its entire length and thereafter portions of the metal providing the lobes 74 are machined away to correspond to the portions of the sleeves 36 between the discharge openings 58, thus enabling flow of matrix resin about the sleeves 36 in all areas along the length thereof.

Diverter bars generally designated by the numeral 80 are provided in alignment with the other row of discharge openings 58 in the sleeve 36. As best seen in FIGS. 5 and 6, the diverter bars have a convex surface extending toward the discharge openings 58 to provide lobes 84 in the areas thereof and they are machined to provide flats 82 therebetween in the solid areas of the sleeves 36 so as to permit flow of resin therebetween.

In addition, to encourage flow of matrix resin through the channel 45 between the sleeves 36, restrictor bars 78 are provided on the walls defining the die chamber 18 to constrict the channels 47 between the sleeves 36 and the large central portion 30 of the die chamber 18. The restrictor bars 78 are conveniently adjustable by means of threaded bolts or the like to permit movement to varying levels within the channel 47.

Turning now to operation of the apparatus, fluid synthetic thermoplastic resin from the main extruder is fed through the feed conduit 20 to the manifold 28 and thence into the upstream portion of the die chamber 18. The resin is then caused to flow about the surfaces of the sleeves 36 through the channels 45, 47.

Simultaneously, differentially colored fluid synthetic thermoplastic resin is fed from the crosshead extruder 12 through the feed conduit 22 to the feed bores 48 of the sleeves 36. The resin then flows at a relatively uniform rate through the series of apertures 56 into the feed passages 52 to the large diameter bores 50. The screws 60 rotating within the large diameter bores 50 discharge the fluid synthetic thermoplastic resin on an intermittent basis through the discharge openings 58a, 58b alternately in each of the sleeves 36, thus producing a discharge of resin which progresses along the length of the discharge openings 58a, 58b. 7

The flow diverter 62 and the flow diverter bars 80 deflect the matrix resin flowing through the channels 45, 47 into the discharge openings 58a, 58b so as to encapsulate the differentially colored resin issuing therethrough. In this manner, the differentially colored resin cordance with the apparatus previously described is illustrated in FIGS. 13 and 14 of the accompanying drawings. The plan view, FIG. 13, shows the pulsed bands of color 86 from the upper sleeve 36 and the pulsed bands of color 88 from the lower sleeve 36, both extending diagonally to the center line of the sheet material and crossing each other at various points to pro duce a basketweave pattern. As can be seen, the beginning and end of the short bands of color extend somewhat parallel to the direction of extrusion because of the variation in the rate of flow of the resin through the discharge openings 58 as the helical lands of the screw to begin to open or to close resin fed in any particular discharge opening 58. The sectional view, FIG. 14, illustrates the disposition of the differentially colored bands within the matrix resin.

Turning now to FIG. 12 of the attached drawings, therein illustrated is an alternate embodiment of the apparatus of the present invention adapted to produce a three color extruded sheet material. To avoid repetition, the same numerals are employed with respect thereto as were employed with respect to the embodiment of FIGS. l-l0. In this embodiment, a second crosshead extruder generally designated by the numeral 112 feeds differentially colored thermoplastic resin to the feed conduit at the side of the die block 14 opposite which the extruder 12 is connected. In this manner, the crosshead extruders 12, 112 each feed one of the sleeves 36 so that the differentially colored bands produced by the two sleeves, i.e., the two layers of differentially colored material, will be of different colors. In this manner, the bands extending in one direction differ in color from the bands extending in the opposite direction.

In the embodiment of FIGS. 13 and 14, the screws 60 in the sleeves 36 are both turning at about the same speed and in opposite directions. In FIG. 15, there is illustrated an alternate embodiment of sheet material which may be produced in accordance with the present invention. The sheet material generally designated by the numeral 116 has a series of elongated bands 186 produced by discharge of the differentially colored synthetic thermoplastic resin through the discharge openings 58a, 58b of one sleeve 36 by the screw 60 which is operating at a very slow rate of rotation. The generally transversely extending short bands of color 188 are produced by discharge of the differentially colored resin through the discharge openings 58 by a screw 60 operating at a relatively high rate of rotation.

Various patterns may be obtained by using different combinations of screws or other intermittent discharge means such as paddle shaped members which will discharge across the entire surface of the discharge openings 58 simultaneously, by varying the relative rates of speed of the intermittent discharge means, by varying their direction of rotation, by oscillating their speed of rotation, etc. Adjustments in the matrix resin flow are conveniently adjusted not only by the pressure developed in the extruder but also by variation in the flow restriction caused by the adjustable restrictor bars 78.

Turning now to FIG. 11, therein illustrated is another embodiment of pressure compensating means comprising a tapered plug generally designated by the numeral 86 and increasing in diameter from the feed conduit end A to the opposite end B. In this manner, the feed bore 48 in the sleeves 36 are constricted as the resin volume decreases to compensate for pressure drop and maintain substantially uniform flow into the feed passage 52 along the length of the bores.

In yet another embodiment, the pressure compensating means may be provided by a slot in a tubular insert in the feed bore which increases in width from the feed conduit end to the opposite end or by milling the feed passage 52 to provide increasing width with increasing distance from the additional feed conduit 22.

The diverter bars may be mounted on the sleeves, or on the walls of the die chamber, or carried by seating end portions in the die block. The restrictor bars are conveniently adjustably mounted in the die block although they may be fixed to the walls of the die chamber or to the sleeves.

Although configurations of the die chamber and sleeves may vary from that illustrated, this particular cross section has been found highly advantageous in avoiding stagnant areas and in ensuring optimum encapsulation of the differentially colored resin. It is essential that the adjacent surfaces be streamlined and permit non-turbulent flow of resin thereby.

As will be readily appreciated, the novel die block assembly of the present invention may be fabricated from relatively few parts and is simple to construct and to v maintain while at the same time ensuring trouble-free operation. Variations in pattern and color may be readily effected and the resultant patterns are substantially uniform along the length of the sheet material and are relatively free from smearing.

Having thus described the invention, I claim;

1. An extrusion assembly for fabricating synthetic plastic sheet material having differentially colored bands therein extending along the length thereof and comprising:

a. an extrusion die block having a chamber therein generally of streamlined non-circular cross section, an elongated extrusion orifice in one surface thereof and a discharge passage between the said chamber and said orifice, said chamber having an enlarged intermediate portion of generally curvilinear configuration extending beyond both sides of the discharge passage and streamlined surfaces tapering from said enlarged portion to said discharge passage;

b. a first feed conduit to said chamber at a point spaced to the opposite side thereof from said discharge passage for supplying a matrix of fluid synthetic thermoplastic resin;

' c. at least one additional feed conduit to said chamber having a portion within said die member extending generally parallel to said extrusion orifice for supplying a differentially colored fluid synthetic thermoplastic resin;

d. a pair of sleeve members in said chamber'extending generally parallel to said extrusion orifice, said sleeve members having streamlined non-circular outer surfaces extending in spaced relationship to the surfaces of said enlarged intermediate portion and being spaced apart to provide a passage therebetween, said sleeve members each having a feed bore therein communicating with said additional feed conduit and a main bore spaced therefrom towards said discharge passage, each sleeve having a flow passage between said feed bore and main bore and a multiplicity of discharge openings extending from said main bore to the outer surface thereof adjacent said discharge passage, said sleeves having pressure compensating means therein to provide substantially uniform flow of resin over the length of said feed and main bores; e. distributor elements seated in said main bores of said sleeves providing intermittent flow of differently colored fluid synthetic thermoplastic resin through said multiplicity of discharge openings;

f. means for driving said distributor elements to provide intermittent flow; and

g. a flow diverter member in said chamber adjacent said discharge passage and having trailing surfaces extending in spaced relationship to the surfaces of said sleeves adjacent said discharge openings of said sleeves with projecting portions at said discharge openings to direct flow of matrix resin towards said discharge openings and leading surfaces converging towards said discharge passage and spaced from said streamlined surfaces of said chamber to provide passages therebetween, whereby matrix fluid synthetic plastic resin entering through said first conduit into the upstream end of said die chamber is caused to flow about and between said sleeve members as a differentially colored fluid synthetic plastic resin being fed through said additional conduit to at least one of said feed bores is intermittently discharged through said discharge openings of said sleeve member and wiped therefrom by the matrix resin to produce encapsulation of the discharged synthetic plastic resin from said sleeve members in the matrix resin flowing thereabout.

2. The extrusion assembly in accordance with claim 1 wherein said chamber of said die block has a configuration defined by concavely curvilinear intermediate surfaces providing said enlarged intermediate portion,

substantially rectilinear trailing surfaces tapering there-- from to said first feed conduit and substantially rectilinear leading surfaces tapering from said curvilinear intermediate surfaces to said discharge passage, said flow diverter member having its trailing end defined by a pair of generally concavely arcuate surfaces with a land therebetween extending toward said passage between said sleeve members and converging leading surfaces extending generally parallel to the rectilinear walls of said die chamber to provide a flow passage therebetween.

3. The extrusion assembly in accordance with claim 2 wherein said trailing and intermediate surfaces of said die block chamber and said trailing end of said flow diverter member define a generally pear shaped configuration and wherein said sleeve members are of generally tear drop configuration so as to cooperate therewith.

4. The extrusion assembly in accordance with claim 1 wherein said sleeve members each have discharge openings arranged in at least two rows along the length thereof.

5. The extrusion assembly in accordance with claim 4 wherein said discharge openings in said rows of each sleeve member are staggered.

6. The extrusion assembly in accordance with claim 4 wherein said rows are spaced generally to opposite sides of the passages between the leading surfaces of said flow diverter member and said die chamber streamlined surfaces.

7. The extrusion assembly in accordance with claim 6 wherein said projecting portions on the trailing surfaces of said flow diverter member extend into the discharge openings of that row adjacent to it and wherein additional flow diverter members are provided in said die chamber which have portions disposed at the discharge openings of the others of said rows.

8. The extrusion assembly in accordance with claim 1 wherein said pressure compensating means in said sleeves comprise manifold tubes seated within said feed bores and having a multiplicity of orifices therein providing communication to the flow passage between said feed bore and main bore, said orifices being of increased size towards the end of said feed bores spaced from said additional feed conduit.

9. The extrusion assembly in accordance with claim 8 wherein said multiplicity of orifices are progressively increasing in size from said feed conduit end to the opposite end of said feed bore.

10. The extrusion assembly in accordance with claim 1 wherein said pressure compensating means comprises an insert member within said feed bore of increased cross section at the end thereof spaced from said additional feed conduit, said insert constricting the said feed bore opening to increase the pressure on resin flowing therethrough and into the flow passage therefrom to said main bore.

11. The extrusion assembly in accordance with claim 10 wherein said insert is of uniformly increasing section from said additional feed conduit end to the opposite end of said feed bore.

12. The extrusion assembly in accordance with claim 1 wherein said sleeve members have ribs on the surfaces thereof spacing them from each other and from the walls of said die chamber.

13. The extrusion assembly in accordance with claim 1 wherein said distributor elements are screws having helical threads adapted to discharge resin intermittently through said discharge openings during rotation thereof.

14. The extrusion assembly in accordance with claim 1 additionally including flow restrictor bars in the passages between said sleeve members and the surfaces of said enlarged intermediate portion of said die chamber.

15. The extrusion assembly in accordance with claim 14 wherein said flow restrictor bars are adjustable to vary the width of the passage therebetween.

16. The extrusion assembly in accordance with claim 1 wherein said discharge openings in said sleeve members have diverging walls to provide increased area adjacent the outer end thereof.

17. The extrusion assembly in accordance with claim 1 wherein there are two additional feed conduits each connected to feed bore in one of said sleeve members, said additional feed conduits being adapted to supply two different streams of differentially colored synthetic thermoplastic resin to said sleeve members.

18. The extrusion assembly in accordance with claim 1 wherein said drive means for said distributor elements drive said distributor elements in opposite directions of rotation.

19. The extrusion assembly in accordance with claim 1 wherein said drive means for said distributor elements drive said distributor elements at different rates of rotation.

20. The extrusion assembly in accordance with claim 1 wherein said sleeve members each have the discharge openings thereof disposed in two rows along the length thereof with the openings of the two rows being staggered, wherein said pressure compensating means comprises manifold tubes seated within said feed bores and having a multiplicity of orifices therein providing comcreased area at the outer end thereof. 

1. An extrusion assembly for fabricating synthetic plastic sheet material having differentially colored bands therein extending along the length thereof and comprising: a. an extrusion die block having a chamber therein generally of streamlined non-circular cross section, an elongated extrusion orifice in one surface thereof and a discharge passage between the said chamber and said orifice, said chamber having an enlarged intermediate portion of generally curvilinear configuration extending beyond both sides of the discharge passage and streamlined surfaces tapering from said enlarged portion to said discharge passage; b. a first feed conduit to said chamber at a point spaced to the opposite side thereof from said discharge passage for supplying a matrix of fluid synthetic thermoplastic resin; c. at least one additional feed conduit to said chamber having a portion within said die member extending generally parallel to said extrusion orifice for supplying a differentially colored fluid synthetic thermoplastic resin; d. a pair of sleeve members in said chamber extending generally parallel to said extrusion orifice, said sleeve members having streamlined non-circular outer surfaces extending in spaced relationship to the surfaces of said enlarged intermediate portion and being spaced apart to provide a passage therebetween, said sleeve members each having a feed bore therein communicating with said additional feed conduit and a main bore spaced therefrom towards said discharge passage, each sleeve having a flow passage between said feed bore and main bore and a multiplicity of discharge openings extending from said main bore to the outer surface thereof adjacent said discharge passage, said sleeves having pressure compensating means therein to provide substantially uniform flow of resin over the length of said feed and main bores; e. distributor elements seated in said main bores of said sleeves providing intermittent flow of differently colored fluid synthetic thermoplastic resin through said multiplicity of discharge openings; f. means for driving said distributor elements to provide intermittent flow; and g. a flow diverter member in said chamber adjacent said discharge passage and having trailing surfaces extending in spaced relationship to the surfaces of said sleeves adjacent said discharge openings of said sleeves with projecting portions at said discharge openings to direct flow of matrix resin towards said discharge openings and leading surfaces converging towards said discharge passage and spaced from said streamlined surfaces of said chamber to provide passages therebetween, whereby matrix fluid synthetic plastic resin entering through said first conduit into the upstream end of said die chamber is caused to flow about and between said sleeve members as a differentially colored fluid synthetic plastic resin being fed through said additional conduit to at least one of said feed bores is intermittently discharged through said discharge openings of said sleeve member and wiped therefrom by the matrix resin to produce encapsulation of the discharged synthetic plastic resin from said sleeve members in the matrix resin flowing thereabout.
 2. The extrusion assembly in accordance with claim 1 wherein said chamber of said die block has a configuration defined by concavely curvilinear intermediate surfaces providing said enlarged intermediate portion, substantially rectilinear trailing surfaces tapering therefrom to said first feed conduit and substantially rectilinear leading surfaces tapering from said curvilinear intermediate surfaces to said discharge passage, said flow diverter member having its trailing end defined by a pair of generally concavely arcuate surfaces with a land therebetween extending towaRd said passage between said sleeve members and converging leading surfaces extending generally parallel to the rectilinear walls of said die chamber to provide a flow passage therebetween.
 3. The extrusion assembly in accordance with claim 2 wherein said trailing and intermediate surfaces of said die block chamber and said trailing end of said flow diverter member define a generally pear shaped configuration and wherein said sleeve members are of generally tear drop configuration so as to cooperate therewith.
 4. The extrusion assembly in accordance with claim 1 wherein said sleeve members each have discharge openings arranged in at least two rows along the length thereof.
 5. The extrusion assembly in accordance with claim 4 wherein said discharge openings in said rows of each sleeve member are staggered.
 6. The extrusion assembly in accordance with claim 4 wherein said rows are spaced generally to opposite sides of the passages between the leading surfaces of said flow diverter member and said die chamber streamlined surfaces.
 7. The extrusion assembly in accordance with claim 6 wherein said projecting portions on the trailing surfaces of said flow diverter member extend into the discharge openings of that row adjacent to it and wherein additional flow diverter members are provided in said die chamber which have portions disposed at the discharge openings of the others of said rows.
 8. The extrusion assembly in accordance with claim 1 wherein said pressure compensating means in said sleeves comprise manifold tubes seated within said feed bores and having a multiplicity of orifices therein providing communication to the flow passage between said feed bore and main bore, said orifices being of increased size towards the end of said feed bores spaced from said additional feed conduit.
 9. The extrusion assembly in accordance with claim 8 wherein said multiplicity of orifices are progressively increasing in size from said feed conduit end to the opposite end of said feed bore.
 10. The extrusion assembly in accordance with claim 1 wherein said pressure compensating means comprises an insert member within said feed bore of increased cross section at the end thereof spaced from said additional feed conduit, said insert constricting the said feed bore opening to increase the pressure on resin flowing therethrough and into the flow passage therefrom to said main bore.
 11. The extrusion assembly in accordance with claim 10 wherein said insert is of uniformly increasing section from said additional feed conduit end to the opposite end of said feed bore.
 12. The extrusion assembly in accordance with claim 1 wherein said sleeve members have ribs on the surfaces thereof spacing them from each other and from the walls of said die chamber.
 13. The extrusion assembly in accordance with claim 1 wherein said distributor elements are screws having helical threads adapted to discharge resin intermittently through said discharge openings during rotation thereof.
 14. The extrusion assembly in accordance with claim 1 additionally including flow restrictor bars in the passages between said sleeve members and the surfaces of said enlarged intermediate portion of said die chamber.
 15. The extrusion assembly in accordance with claim 14 wherein said flow restrictor bars are adjustable to vary the width of the passage therebetween.
 16. The extrusion assembly in accordance with claim 1 wherein said discharge openings in said sleeve members have diverging walls to provide increased area adjacent the outer end thereof.
 17. The extrusion assembly in accordance with claim 1 wherein there are two additional feed conduits each connected to feed bore in one of said sleeve members, said additional feed conduits being adapted to supply two different streams of differentially colored synthetic thermoplastic resin to said sleeve members.
 18. The extrusion assembly in accordance with claim 1 wherein said drive means for said distributor elements drive said distributor eLements in opposite directions of rotation.
 19. The extrusion assembly in accordance with claim 1 wherein said drive means for said distributor elements drive said distributor elements at different rates of rotation.
 20. The extrusion assembly in accordance with claim 1 wherein said sleeve members each have the discharge openings thereof disposed in two rows along the length thereof with the openings of the two rows being staggered, wherein said pressure compensating means comprises manifold tubes seated within said feed bores and having a multiplicity of orifices therein providing communication to the flow passage between said feed bore and main bore, said orifices being of increasing size towards the end of said feed bores spaced from said additional feed conduit, and wherein said discharge openings are defined by diverging walls to provide an increased area at the outer end thereof. 